Differential Case & Ring Gear - Traction-LOK®: Assembly

CAUTION: 118 ml (4 oz) of the Additive Friction Modifier must be used in the axle.

Lubricate each steel clutch plate and soak all the friction plates for no less than 15 minutes.
- Use Additive Friction Modifier C8AZ-19B546-A or equivalent meeting Ford specification EST-M2C118-A

CAUTION: Do not mix the clutch plates, clutch discs or shim from one side with the other.

Fig 1: Identifying Differential Clutch Packs

Courtesy of FORD MOTOR CO.

Assemble the differential clutch packs (without the shims) on their respective differential side gear.

CAUTION: Use the correct mandrel with the special tool.

Fig 2: Identifying Differential Clutch Pack, Side Gear & Differential Clutch Gauge

Courtesy of FORD MOTOR CO.

Place the base portion of the special tool in a vise. Install the differential side gear and differential clutch pack (without the shim) on the tool.
Position the special tool hand-tight on top of the differential clutch pack.

Fig 3: Installing Center Of Differential Clutch Gauge Over Disc & Differential Clutch Pack
Courtesy of FORD MOTOR CO.
Install the special tool over the disc and differential clutch pack.

Fig 4: Installing Top Of Differential Clutch Gauge Over Disc & Differential Clutch Pack
Courtesy of FORD MOTOR CO.
Install the nut.

Fig 5: Tightening Differential Clutch Gauge Nut
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Select and insert the thickest feeler gauge blade that will enter between the tool and the differential clutch pack. The reading will be the thickness of the new clutch shim.

Fig 6: Identifying Differential Clutch Shim Numbers & Thicknesses
Courtesy of FORD MOTOR CO.

Fig 7: Measuring Distance Between Differential Clutch Gauge & Differential Clutch Pack
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Remove the special tool from the differential clutch pack and differential side gear assembly.
Install the shim(s) on the differential clutch pack and differential side gear assembly.
Install the differential side gear assemblies in the differential case.

Fig 8: Installing Differential Side Gear Assemblies In Differential Case
Courtesy of FORD MOTOR CO.
Install the differential pinion gear and differential pinion thrust washer assemblies in the differential case.

Fig 9: Installing Differential Pinion Gear & Differential Pinion Thrust Washer Assemblies
Courtesy of FORD MOTOR CO.
Using a soft-faced hammer, install the differential clutch spring.

Fig 10: Installing Differential Clutch Spring
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Install the differential pinion shaft and install a new bolt finger-tight.

Fig 11: Identifying Differential Pinion Shaft & Bolt
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Mount the differential case and the special tool in a vise. Using the special tool, check the torque necessary to rotate one differential side gear.
- If reusing the original clutch plates, the initial minimum break-away torque must be no less than the specification. The minimum rotating torque necessary to keep the differential side gear turning with new clutch plates may vary.
Fig 12: Checking Torque Necessary To Rotate One Differential Side Gear
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Using the special tool, install the differential bearings.

Fig 13: Installing Differential Bearing
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Position the differential ring gear and the differential case. Align the bolt holes by starting two bolts through the holes in the differential case and the differential ring gear. Press the differential ring gear on the differential case.

Fig 14: Installing Differential Ring Gear
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Install the bolts.
- Apply Stud and Bearing Mount E0AZ-19554-BA or equivalent meeting Ford specification WSK-M2G349-A1 to bolt threads.
Fig 15: Tightening Differential Ring Gear Bolts
Courtesy of FORD MOTOR CO.
Install the differential assembly. For additional information, refer to DIFFERENTIAL CASE .